Furniture item and a method for attaching webbing thereto

ABSTRACT

A furniture item and a method for its manufacture, the item comprising at least one support portion, said at least one support portion ( 24,26 ) comprising a receiving frame ( 30 ) and a support member ( 50 ) comprising a webbing ( 54 ) made of flexible material fitted at its edges with frame-engaging profiles ( 56 ) formed with first engaging members ( 66 ) for secure engagement with corresponding second engaging members ( 32 ) of the receiving frame ( 30 ); the invention characterized in that said frame-engaging profiles ( 56 ) are integrally molded with said webbing ( 54 ).

FIELD OF THE INVENTION

The present invention is generally concerned with furniture and morespecifically it is concerned with applying a webbing such as a seatportion, a backrest, etc. to the furniture frame.

Hereinafter in the specification the term “furniture” denotes any typeof furniture used for seating such as, for example, chairs, armchairs,rocking chairs, stools, seats, sofas, garden furniture, etc.

The term “webbing” as used herein in the specification and claimsdenotes a flexible surface of the furniture suitable for supporting aperson using the furniture, e.g. a seat, a backrest, a leg rest, etc.Such webbing may be typically made of a uniform material or made offlaps, typically transversing one another.

BACKGROUND OF THE INVENTION

A variety of methods exist for attaching webbing to a furniture's frame,to thereby provide a comfortable and pleasant support surface serving,e.g. as a seat portion or a backrest.

Examples of disclosures of such methods are, for example, U.S. Pat. Nos.3,512,834, 5,015,034, 5,338,091 and 5,662,383.

It is a primary object of the present invention to provide a furniturewherein the webbing material is attached to the frame of the furniturein a fast, easy and cost effective fashion. This is achieved byintegrally molding of the webbing with profiles which are in turn easilyengageable with a receptacle of the furniture's frame.

SUMMARY OF THE INVENTION

According to the present invention there is provided a furniture itemcomprising at least one support portion, said at least one supportportion comprising a receiving frame and a support member comprising awebbing made of flexible material fitted at its edges with frameengaging profiles formed with first engaging members for secureengagement with corresponding second engaging members of the receivingframe; the invention characterized in that said frame engaging profilesare integrally molded with said webbing.

The webbing may be a sheet of material or a mesh or a plurality ofstraps, typically transversely extending.

The webbing is made of or coated with a thermoplastic material. Inaccordance with one of its embodiments, the webbing is a mesh of fabricwoven of polymeric yarns coated with thermoplastic material and theframe-engaging profiles are made of material having a substantially lowcoefficient of thermal expansion (CTE). The frame-engaging profiles aremade of a thermoplastic material which is injection moldable and heatweldable with the coating of the webbing. However, according to otherembodiments, the frame-engaging profiles are made of non-thermoplasticmaterial though moldable, e.g. metal, composite materials, etc.

In accordance with one particular embodiment the frame-engaging profilesform a closed frame structure corresponding with the shape of thereceiving frame. However, in accordance with another embodiment, theframe-engaging profiles are non uniform and are attachable one by one tothe receiving frame.

In order to increase attachment of the frame-engaging profiles to thewebbing material, it is advantageous that the webbing has a roughenedtexture at least at zones attached to the frame-engaging profiles.Alternatively, or in addition, this may be obtained by forming saidzones with pores, whereby material of the frame-engaging profilespenetrates through the webbing to thereby increase mechanical engagementtherebetween. Furthermore, the frame-engaging profile may sandwich edgesof the webbing whereby such sandwiching may be obtained by penetrationthrough the webbing.

In accordance with one particular embodiment the frame-engaging profilesare detachable from the receiving frame whereby the support member maybe removed, e.g. for cleaning and maintenance or replaced. Suchremovable connection may be, for example, a snap-type engagement.

The invention is further concerned with a method for manufacturing asupport portion for a furniture item, said support portion comprising areceiving frame and a support member comprising a webbing made offlexible material fitted at its edges with frame engaging profilesformed with first engaging members for secure engagement withcorresponding second engaging members of the receiving frame; the methodincludes integrally molding of the said frame engaging profiles with thewebbing.

In accordance with the method of the invention, the webbing is made of amesh fabric woven of polymeric yarns coated with a thermoplasticmaterial whereby the frame-engaging profiles are made of a materialhaving a substantially low coefficient of thermal expansion (CTE) andwherein during molding the frame-engaging profiles are heat welded torespective portions of the webbing.

In accordance with a particular embodiment, during the molding process,the material of the frame-engaging profiles penetrates through thewebbing to thereby increase mechanical engagement therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carriedout in practice, an embodiment will now be described, by way of anon-limiting example only, with reference to the accompanying drawings,in which:

FIG. 1 is an isometric view of a furniture, a garden chair in thepresent example, in accordance with the present invention;

FIG. 2A is an isometric top view of a receiving frame removed from thechair of FIG. 1;

FIG. 2B is a top view of the receiving frame seen in FIG. 2A;

FIG. 3A is a top isometric view of the support member removed from thehair, in a position as removed from the mold;

FIG. 3B is a bottom isometric view, illustrating the support member ofFIG. 3A in a position prior to engaging with the receiving frame ofFIGS. 3A and 3B;

FIG. 4A is an enlargement of the portion marked III in FIG. 3A;

FIG. 4B is an enlargement of the portion marked III in FIG. 3A as seenfrom below; and

FIG. 5 is a local section along lines V-V in FIG. 1, illustrating howthe support portion is engaged with the furniture item.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an armchair generally designated 10 of the typecommonly used as garden furniture, and which comprises several framecomponents namely legs 12, armrests 14, a seat 16, and a backrest 18,which in the present example is inclinable between several respectivepositions.

In the present embodiment the frame components are made of moldedplastic material though this is not necessarily the case and the framecomponents may be made, for example, of wood, metal, etc., or of acombination of several such materials.

Furthermore, the chair may be collapsible and/or stackable, as knownwith such plastic chairs which are often referred to also as “gardenfurniture” and “garden chairs”, respectively.

As can further be seen in FIG. 1, the seat 16 and the backrest 18comprise a support portion 24 and 26, respectively, which as will beexplained hereinafter in more detail are made of flexible webbingattached to the respective frame.

For the sake of clarity only, further reference will be made to the seat16, though the skilled reader will appreciate that the same arrangementsas will be hereinafter disclosed in detail, could apply to the back rest18 and also to other furniture articles (not shown).

Embedded within the seat frame 16 there is a receiving frame 30(independently shown in FIGS. 2A and 2B) which in the present embodimentis a rectangle though other shapes are possible just as well.

Receiving frame 30 may be integrally formed with the respective framemember (seat 16 or backrest 18) e.g. in an injection molding process, orelse it may be fixedly attached thereto. For the sake of clarity, in thepresent example, the receiving frame has been removed from the seat 16.

As can be seen in FIGS. 2A and 2B, the receiving frame 30 comprises aperipheral recess 32 substantially vertically extending from a top edge34 towards a bottom edge 36 (FIG. 2A) with a plurality of openings 40formed at a bottom surface of the recess 32.

The receiving frame 30 is made of a rigid material and has a webbingsupport surface 42 and a gradually inclined or curved surface 44 toallow some deformation of a webbing under load, i.e. weight of a personseated on the chair.

Further attention is now directed to FIGS. 3A; 3B and 4A; 4Billustrating a support member generally designated 50 comprising asurface of flexible webbing 54 (see also FIGS. 1 and 5) andframe-engaging profiles 56 integrated with the webbing 54, as willbecome apparent hereinafter.

The webbing 54 is made of mesh fabric woven of polymeric yarns coatedwith a thermoplastic material, e.g. PVC. Such mesh is often referred toas Textilene® and is available in different colors and density.

In accordance with a particular embodiment the webbing 54 has aroughened surface at least at its peripheral zones (59 in FIG. 4A) wherethe frame-engaging profiles 56 extend. In addition, or alternatively,said peripheral zone 59 may comprise pores to further increasemechanical attachment with the frame-engaging profiles, as will beexplained hereinafter.

The frame-engaging profiles 56 extend along edges of the webbing 54. Inthe present example the profiles 56 are individual profiles though inaccordance with other embodiments (not shown) the profiles may be formedinto a rigid frame consisting of two or more such frame-engagingprofiles or, each edge of the webbing may comprise severalframe-engaging profiles rather than a continuous profile as illustratedin the annexed figures.

The frame-engaging profiles 56 comprise a ruler portion 62 correspondingin shape with the recess 32 of the receiving frame 30 such that at theassembled position (FIG. 5) the ruler conceals the recess 32.

Each of the profiles 56 comprises a plurality if first engaging members66 fitted at their free end with a lug 68 for snap engaging withinrecesses 40 of the receiving frame 30, as seen in FIG. 5.

The support member 50 is manufactured in an injection molding processwhere a sheet of webbing material 54 is applied into the mold (notshown) where injection moldable, thermoplastic material (e.g. ABS) isinjected into the mold and whereby molten material flows through thepores of the webbing 54 allowed to expand into preformed support ribs 70which may also be in the form of support surfaces (not shown). In such aprocess the frame-engaging profiles 56 are molded and integrated withthe webbing 54 such that attachment of the profiles 56 to the webbing 54is obtained by both heat welding of the thermoplastic material of thewelded profiles which heat welds to the thermoplastic coating of thewebbing and further by mechanical attaching, i.e. penetration of themolded material through the pores of the webbing and further by thesandwiching of the ribs 70. It is appreciated that rather than ribs 70the edges of webbing 54 may be entirely sandwiched by correspondingportions of the frame-engaging profiles (not shown).

The frame-engaging profiles 54 are made of a material having asubstantially low coefficient of thermal expansion (CTE) whereby afterwithdrawal of the integral support member 50 from the mold, theframe-engaging profiles substantially do not deform, retaining thewebbing 54 in an essentially flat position. FIG. 3A illustrates theposition of the support member 50 as it is withdrawn from the mold.

Engaging the support member 50 to the receiving member 30 is carried outby introducing the first engaging members 56 into the correspondingrecesses 32 to thereby facilitate snap engagement of lugs 68 withinrecesses 40. It is appreciated that depending on the particular designthe snap engagement may be disengaged, e.g. by the aid of a tool such asa screwdriver. It is further appreciated that other forms of engagementmay be utilized, e.g. locking eyes projecting from the first engagingmembers engageable with corresponding locking eyes of the secondengaging members of the receiving frame, said eyes engageable with oneanother, for example by a pin extending through the eyes, etc. (thisarrangement is not shown).

Tensioning the web over the receiving frame is obtained by ensuring thatthe distance between opposed recesses 32 of the receiving frame isslightly larger than the respective distance between opposedframe-engaging profiles 56 whereby engagement of the support member withthe receiving frame requires some amount of force.

Whilst the description hereinabove describes a specific embodiment andseveral applications of the invention, it will be understood by thoseskilled in the art that the invention is not limited thereto and thatother variations may be possible, without departing from the scope andthe spirit of the invention herein disclosed. For example, a variety ofengagements may be suited for fixedly engaging between the supportmember and the receiving frame. Otherwise, the support member may beformed in a variety of shapes and patterns and the support member may bedesigned for easy removal, etc.

1. A furniture item comprising at least one support portion, said atleast one support portion comprising a receiving frame and a supportmember comprising a webbing made of flexible material fitted at itsedges with frame-engaging profiles formed with first engaging membersfor secure engagement with corresponding second engaging members of thereceiving frame; the invention characterized in that said frame-engagingprofiles are integrally molded with said webbing.
 2. A furniture itemaccording to claim 1, wherein the webbing is a sheet of material.
 3. Afurniture according to claim 1, wherein the webbing is a mesh.
 4. Afurniture item according to claim 1, wherein the webbing is made of aplurality of transversally extending straps.
 5. A furniture according toclaim 1, wherein the webbing is made of or coated with a thermoplasticmaterial.
 6. A furniture item according to claim 1, wherein the webbingis made of mesh fabric woven of polymeric yarns coated withthermoplastic material.
 7. A furniture item according to claim 1,wherein the frame-engaging profiles are made of a material having asubstantially low coefficient of thermal expansion (CTE).
 8. A furnitureitem according to claim 1, wherein the frame-engaging profiles are madeof thermoplastic material.
 9. A furniture item according to claim 1,wherein the webbing has a roughened texture at least at zones attachedto the frame-engaging profiles.
 10. A furniture item according to claim1, wherein the webbing has a porous texture at least at zones attachedto the frame-engaging profiles.
 11. A furniture item according to claim1, wherein the frame-engaging profiles form a closed frame structurecorresponding with the receiving frame.
 12. A furniture item accordingto claim 1, wherein the frame-engaging profiles extend substantiallyalong edges of the webbing.
 13. A furniture item according to claim 1,wherein material of the frame-engaging profiles penetrates through thewebbing to thereby increase mechanical engagement therebetween.
 14. Afurniture item according to claim 1, wherein the frame-engaging profilesare heat welded to respective portions of the webbing.
 15. A furnitureitem according to claim 1, wherein at least some portions of zones ofthe frame-engaging profiles attached to the webbing sandwich thewebbing.
 16. A furniture item according to claim 1, wherein thefurniture is a garden furniture.
 17. A furniture item according to claim1, wherein the frame-engaging profiles are detachable from the receivingframe.
 18. A furniture item according to claim 1, wherein the firstengaging members of the frame-engaging profiles are snapingly engagedwith the second engaging members of the receiving frame.
 19. A furnitureitem according to claim 1, wherein the first engaging members of theframe-engaging profiles project into the second engaging members of thereceiving frame and are lockingly engaged with one another.
 20. Afurniture item according to claim 1, wherein the webbing is tensionedupon engaging the frame-engaging profiles with the receiving frame. 21.A furniture item according to claim 1, wherein the receiving frame isintegral with a frame portion of the furniture.
 22. A furniture itemaccording to claim 1, wherein the receiving frame comprises openings forreceiving the frame-engaging profiles and the frame-engaging profilesare formed with concealing portions, wherein upon engagement saidconcealing portions close the openings of the receiving frames.
 23. Afurniture item according to claim 1, wherein prior to engagement of thesupport member to the support frame a plane of the webbing and a planeof the frame-engaging profiles are substantially parallel, whilst at theengaged position said panes intersect one another.
 24. A method formanufacturing a support portion for a furniture item, said supportportion comprising a receiving frame and a support member comprising awebbing made of flexible material fitted at its edges withframe-engaging profiles formed with first engaging members for secureengagement with corresponding second engaging members of the receivingframe; the method includes integrally molding of the said frame-engagingprofiles with the webbing.
 25. A method according to claim 24, whereinthe webbing is made of mesh fabric woven of polymeric yarns coated witha thermoplastic material.
 26. A method according to claim 24, whereinthe frame-engaging profiles are made of a material having asubstantially low coefficient of thermal expansion (CTE).
 27. A methodaccording to claim 24, wherein during the molding process the materialof the frame-engaging profiles penetrates through the webbing to therebyincrease mechanical engagement therebetween.
 28. A method according toclaim 24, wherein during molding the frame-engaging profiles are heatwelded to respective portions of the webbing.
 29. A method according toclaim 24, wherein at least some portions of zones of the frame-engagingprofiles attached to the webbing sandwich the webbing.
 30. A methodaccording to claim 24, wherein the frame-engaging profiles areconnectable to the receiving frame in a detachable fashion.
 31. A methodaccording to claim 24, comprising the following steps: (a) Obtaining amold; (b) Applying the webbing material into the mold; (c) Closing themold and injecting molten material into the mold to thereby mold theframe-engaging profiles integrated with said webbing; (d) Removing theintegrated support portion from the mold.
 32. A method according toclaim 24, wherein the webbing is a sheet of material.
 33. A methodaccording to claim 24, wherein the webbing is made of a plurality oftransversally extending straps.
 34. A method according to claim 31,wherein during the molding process plane of the webbing and a plane ofthe frame-engaging profiles are parallel.
 35. A method according toclaim 31, wherein during step (c) molten material of the frame-engagingprofiles penetrates through the webbing to thereby increase mechanicalengagement therebetween.
 36. A support member for fitting to a supportportion of a furniture item, said support member comprising a flexiblewebbing integrally molded with frame-engaging profiles engageable withcorresponding engaging members of a receiving frame of the supportportion.
 37. A support member according to claim 31, wherein the webbingis made of or coated with a thermoplastic material.
 38. A support memberaccording to claim 36, wherein the webbing is made of mesh fabric wovenof polymeric yarns coated with a thermoplastic material.
 39. A supportmember according to claim 36, wherein the frame-engaging profiles aremade of a material having a substantially low coefficient of thermalexpansion (CTE).